As part of the Modutec group Avantis have recently carried out the full installation of a Ballast Water Treatment System (BWTS), including associated piping, electrical and instrumentation works for The Pasha Group within a tight time schedule and project budget.
Avantis Marine was awarded the installation of one (1) Alfa Laval Pure Ballast 3.1 750m3/hr Ballast Water Treatment System (BWTS) and associated piping, electrical and instrumentation works. Avantis Marine main installation scopes were to include:
- Material Supply & Prefabrication.
- Mechanical & Electrical Installation – In service with riding squad.
- Commissioning Assistance.
Seven Phase Installation Approach
Based on the Avantis Marine feasibility study the below design documentation and criteria was completed to the required classification standards: Alfa Laval Pure Ballast 3.2 1000 Document, P&ID’S, pipework isometrics, foundation drawings, overboard drawings, electrical drawings & cable pull list.
Once all design approved drawings & P&ID’s were compiled and approved by both Class and the client, our internal procurement team procured all installation materials as per Class standard and required material grades (With correct and class approved material certification): pipework, foundation steelwork, valves, cable, bolting & gaskets. Through the use of JIT procurement strategy all materials arrived prior to installation works.
Foundations – Fabrication & Installation
Once all procurement was completed our internal pre-fabrication/ installation team was dedicated on the fabrication & installation of the following – filter foundation, control cabinet foundation, lamp driver cabinet foundation, UV reactor cabinet foundation, CIP module foundation & backflush pump foundation.
After installation of the required foundations and supports our installation team focused on the equipment installation process, comprising of:
- UV reactor
- CIP module
- Filter backflush pump
- Control cabinet
- Lamp driver cabinet
New foundations and bedplates for equipment will be constructed and installed on existing structure, with equipment mounted and bolted in place. Damage on any steel surface due to burning and welding shall be cleaned with 3pt surface treatment and shall be painted as originally specified or in accordance with makers recommended practice. Any surface preparation prior to painting will be Pt3. Any paint required to be provided free issue by Client. New pad eyes for maintenance of the filter will be installed should there be no suitable exiting rigging points available.
Pipework – Fabrication & Installation
Ballast System piping within the engine room is SMLS, Hot dip galvanized and new BWTS piping to be A106 Gr. B or the equivalent. BWTS Inlet –A106 Gr. B, Hot dip galvanized –DN350. BWTS Outlet –A106 Gr. B, Hot dip galvanized –DN350.
DN15 CS Instrument Airline will be taken from a suitable tie-in near the proposed equipment location, with new DN15 header to be installed to service BWTS system. Instrument air will be provided for the following equipment:
- Pneumatic control valves
- Pneumatic butterfly valves
- CIP unit
For the Supply and install power and control cables, cable trays and MCT coaming penetration between BWTS components, cabinets, switchboards, distribution boards in engine room.
Marine rated power cable from the main switchboard will be run to and from the BIO-SEA supplied electrical control cabinet (incorporating existing cable tray/ ladder where possible) to services of the BWTS control panels to be installed as per maker’s instructions. To be supported with new steel frame constructed of angle bar. The steel frame support to be fitted and welded on existing structural elements.
All necessary panels and ceiling cover to be removed and refitted after installation, as deemed necessary. Existing cable penetrations will be utilised for all power/signal cables, with cable existing cable trays used as much as possible to minimise material costs.
Avantis have allowed for 2 x Men (1 x Mechanical & 1 x Electrical) to assist OEM & Client with final commissioning works for 2 days.
- Offline commissioning tests all installation scopes.
- Completion acceptance of all installation works.
- Completion acceptance of all piping connections.
- Completion acceptance of all electrical works / Electrical Test Reports.
- Proof testing piping connections & valve operations.
- Shipboard function test of BWTS with crew’s assistance.
- Final commissioning with OEM & Class Surveyor in attendance.
Commissioning and testing will be carried out by Alfa Laval procedure in accordance to the Class approved commissioning and testing program of BWTS through an approved ITP, to the satisfaction of Class Surveyor and Owner’s representative. Avantis representatives will be present throughout the shipboard function test. An offline commissioning test will be carried out for all Avantis installation scopes.
To find out more about Modutec and our Energy Performance & Clean Technologies click on the following link – Energy Performance & Clean Technologies